KYMCO ZX User manual

ZX / SCOUT

PREFACE

This Service Manual describes the technical feature.s and servicing

procedures for the KYMCO ZX / SCOUT 50.

In this manual, many illustrations and drawings are used to help

servicemen have better understanding.

Section 2 contains the service precautions for all operations and

troubleshooting stated in this manual. Read them carefully before starting

any operation.

Section 3 describes the inspection/adjustment procedures, safety rules and

service information for each part, starting from periodic maintenance.

Sections 4 through 16 give instructions for disassembly, assembly and

inspection of lubrication system, engine, fuel system and electrical

equipment.

Section 17 is the maintenance and inspection directions for the evaporative/

exhaust emission control system. Most sections start with an assembly or

system illustration and troubleshooting for the section. The subsequent

pages give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

MARCH 2000

1. SPECIFICATIONS

ZX / SCOUT

1TABLE OF CONTENTS

SPECIFICATIONS.................................................................................. 1

GENERAL INFORMATION .................................................................. 2

INSPECTION/ADJUSTMENT............................................................... 3

LUBRICATION SYSTEM....................................................................... 4

ENGINE REMOVAL/INSTALLATION................................................. 5

CYLINDER HEAD/CYLINDER/PISTON.............................................. 6

A.C. GENERATOR ................................................................................. 7

KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY....... 8

FINAL REDUCTION............................................................................... 9

CRANKCASE/CRANKSHAFT...............................................................10

CARBURETOR .......................................................................................11

FRAME COVERS....................................................................................12

STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/

FRONT SHOCK ABSORBER/FRONT FORK......................................13

REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER..............14

ELECTRICAL EQUIPMENT.................................................................15

INSTRUMENT/SWITCHES/LIGHTS....................................................16

EVAPORATIVE/EXHAUST EMISSION CONTRAL SYSTEM...........17

1. SPECIFICATIONS

ZX 50

SPECIFICATIONS

Name & Model SC10AS

Overall length (mm) 1792

Overall width (mm) 690

Overall height (mm) 1053

Wheel base (mm) 1225

Engine type Air cooled 2-stroke

Displacement (cc) 49.4 cc

Net weight (kg)

92.5

Seating capacity 2 riders (110kg)

Gross weight(kg)

150

Front wheel

120/70-12

Tires Rear wheel

120/70-12

Ground clearance (mm) 170

Braking distance (m)

(Initial speed Km/h) 7m (30km/h)

Min. turning radius (mm) 1940

Starting system Starting motor &

kick starter

Fuel type Gasoline, 2-stroke

motor oil

Cylinder arrangement Single cylinder, flat

Combustion chamber type Semi-sphere

Valve arrangement Reed valve & piston

Bore x stroke (mm) 39 x 41.4

Compression ratio 7.3 : 1

Compression pressure

(kg/cm²rpm) 11.5kg/cm²

Max. output (kw/rpm) 3.75/7000kw/rpm

Max. torque (kg-m/rpm) 4.5/6500 kg m/rpm

Open Automatic controlled

Intake Close Automatic controlled

Port Open 

timing Exhaust Close 

Open 

Scavenge

Close 

Idle speed (rpm)2100±100

Lubrication type Separate type

Oil pump type Plunger type

Oil filter type Full-flow filtration

Lubrication oil capacity (liter) 0.80

Air cleaner type & No. Wet, single

Fuel capacity (liter) 4.9

Type Plunger type

Carburetor Piston dia. (mm) 

Venturi dia. (mm) 14

Ignition system type CDI electromagnetic

Ignition

Ignition timing F mark 15.5°±2°BTDC/2000rpm

Spark NGK BR8HSA

plug ND

Spark plug gap (mm) 0.6 0.7

Battery capacity 12V3AH

Power to transmission gear Power-transmission

gear-clutch

Reduction ratio of power to

transmission 

Clutch type Dry multi-disc clutch

Transmission gear operation

type Automatic centrifugal

type

Transmission ratio 1 spe



Reduction

Type Two-stage reduction

gear 1st reduction ratio 

2nd reduction ratio



Transmission gear type Non-stage transmission

Tire pressure

Front wheel

1.50

1.75

(kg/cm²)Rear wheel

1.75 2.25

Turning angle Right & left 45°

Brake system

Front wheel

Expanding/hydraulic

type Rear wheel

Expanding

Suspension

Front wheel

Telescope

type Rear wheel

Unit swing

Shock absorber

Front wheel

Telescope

type Rear wheel

Unit swing

Frame type Pipe under bone

CO 4.5%Exhaust

emission

concentration HC 7000ppm Max

2. GENERAL INFORMATION

ZX / SCOUT

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

ENGINE SERIAL NUMBER/IDENTIFICATION............................2-1

SERVICE PRECAUTIONS ............................................................2-2

SERVICE INFORMATION............................................................2-6

TORQUE VALUES........................................................................2-8

SPECIAL TOOLS ..........................................................................2-9

LUBRICATION POINTS...............................................................2-11

WIRING DIAGRAM......................................................................2-12

CABLE & HARNESS ROUTING...................................................2-13

TROUBLESHOOTING ..................................................................2-17

2. GENERAL INFORMATION

ZX / SCOUT

ENGINE SERIAL NUMBER/IDENTIFICATION

Location of Engine Serial Number

2. GENERAL INFORMATION

ZX / SCOUT

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when reassembling.

nWhen tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

nUse genuine parts and lubricants.

nWhen servicing the motorcycle, be sure to use

special tools for removal and installation.

nAfter disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

nApply or add designated greases and

lubricants to the specified lubrication points.

nAfter reassembly, check all parts for proper

tightening and operation.

nWhen two persons work together, pay

attention to the mutual working safety.

nDisconnect the battery negative (-) terminal

before operation.

nWhen using a spanner or other tools, make

sure not to damage the motorcycle surface.

nAfter operation, check all connecting points,

fasteners, and lines for proper connection and

installation.

nWhen connecting the battery, the positive (+)

terminal must be connected first.

nAfter connection, apply grease to the battery

terminals.

nTerminal caps shall be installed securely.

nIf the fuse is burned out, find the cause and

repair it. Replace it with a new one according

2. GENERAL INFORMATION

ZX / SCOUT

to the specified capacity.

nAfter operation, terminal caps shall be installed

securely.

nWhen taking out the connector, the lock on

the connector shall be released before

operation.

nHold the connector body when connecting or

disconnecting it.

nDo not pull the connector wire.

nCheck if any connector terminal is bending,

protruding or loose.

nThe connector shall be inserted completely.

nIf the double connector has a lock, lock it

at the correct position.

nCheck if there is any loose wire.

nBefore connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

nCheck the double connector cover for proper

coverage and installation.

nInsert the terminal completely.

nCheck the terminal cover for proper coverage.

nDo not make the terminal cover opening face

up.

nSecure wire harnesses to the frame with their

respective wire bands at the designated

locations.

Tighten the bands so that only the insulated

surfaces contact the wire harnesses.

nAfter clamping, check each wire to make sure

it is secure.

Easy confirm

2. GENERAL INFORMATION

ZX / SCOUT

nDo not squeeze wires against the weld or its

clamp.

nAfter clamping, check each harness to make

sure that it is not interfering with any moving or

sliding parts.

nWhen fixing the wire harnesses, do not make it

contact the parts which will generate high heat.

nRoute wire harnesses to avoid sharp edges or

corners. Avoid the projected ends of bolts

and screws.

nRoute wire harnesses passing through the side

of bolts and screws. Avoid the projected

ends of bolts and screws.

nRoute harnesses so they are neither pulled

tight nor have excessive slack.

nProtect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner.

nWhen rubber protecting cover is used to

protect the wire harnesses, it shall be installed

securely.

nDo not break the sheath of wire.

nIf a wire or harness is with a broken sheath,

repair by wrapping it with protective tape or

replace it.

nWhen installing other parts, do not press or

squeeze the wires.

nAfter routing, check that the wire harnesses

are not twisted or kinked.

Don’t touch

2. GENERAL INFORMATION

ZX / SCOUT

nWire harnesses routed along with handlebar

should not be pulled tight, have excessive

slack or interfere with adjacent or surrounding

parts in all steering positions.

nWhen a testing device is used, make sure to

understand the operating methods thoroughly

and operate according to the operating

instructions.

nBe careful not to drop any parts.

nWhen rust is found on a terminal, remove the

rust with sand paper or equivalent before

connecting.

nSymbols:

The following symbols represent the servicing

methods and cautions included in this service

manual.

:Apply engine oil to the

specified points. (Use

designated engine oil for

lubrication.)

:Apply grease for lubrication.

:Use special tool.

:Caution

:Warning

(ð12-3) :Refer to page 12-3.

Engine Oil

Grease

Special

Remove the rest

2. GENERAL INFORMATION

ZX / SCOUT

SERVICE INFORMATION

ENGINE

Standard (mm) Service Limit (mm)

Item SC10AS SC10AS

Cylinder head warpage 0.10

PistonO.D.(5mm from bottom of piston skirt) 38.955 38.970 38.90

Cylinder-to-piston clearance 0.10

Piston pin hole I.D. 12.002 12.008 12.03

Piston pin O.D. 11.994 12.0 11.98

Piston-to-piston pin clearance ←←

Piston ring end gap (top/second) 0.10 0.25 0.40

Connecting rod small end I.D. 17.005 17.017 17.03

Cylinder bore 39.039.025 39.05

Drive belt width 18 17

Drive pulley collar O.D. 20.01 20.025 ←

Movable drive face ID. 20.035 20.085 19.97

Weight roller O.D. 13.0 12.4

Clutch outer I.D. 107 107.2 107.5

Driven face spring free length 87.9 82.6

Driven face O.D. ←←

Movable driven face I.D. ←←

Connecting rod big end side clearance ←←

Connecting rod big end radial clearance ←←

Crankshaft runout A/B ←

CARBURETOR SC10AS

Venturi dia. 14mm

Identification number 014A

Float level 5.0mm

Main jet #80

Slow jet #35

Air screw opening 1 ±¼

Idle speed 2100±100rpm

Throttle grip free play 2 6mm

Jet needle clip notch 1st notch

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